Carbon dioxide booster pump control system and method

Abstract

The invention discloses a carbon dioxide booster pump control system and method, particularly relates to the technical field of carbon dioxide booster pump control, and aims at transient interference pulses caused by starting and stopping of a pump body in the batch production process, millisecond-level timestamp mapping is adopted to achieve interference and steady-state pulse separation. Performing sliding median filtering on the steady-state pulse, extracting a window center peak value, and performing incremental accumulation in sequence to obtain operation accumulated flow in real time; based on the last peak time label, synchronously collecting temperature and pressure measurement values, generating a correction amount through a predefined temperature correction function and a user-defined pressure correction function, adding the correction amount according to a fixed weight, and converting the correction amount into a compensation pulse count through pulse-volume conversion to correct an accumulated error; high-precision flow metering and compensation are achieved through the synergistic effect of start-stop interference elimination, filtering peak value extraction and a correction function, and the reliability of a carbon dioxide booster pump control system under the complex working condition is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of carbon dioxide booster pump control, and more particularly, to a carbon dioxide booster pump control system and method. Background Art

[0002] Currently, most of the carbon dioxide booster pump control systems on the market use an architecture that separates touch-screen software from sensors, supports user login management and pipeline parameter configuration, and the interface is divided into two functional areas: manual operation and background maintenance. It can display multiple operating states such as flow, pressure, and temperature in real time; the system provides constant flow and constant pressure mode switching. In constant flow mode, the flow rate increases in stages according to the target flow rate set by the user and maintains a stable output. In constant pressure mode, the target pressure, control range and flow upper limit can be input. The equipment automatically adjusts the actuator based on the feedback parameters to maintain the system pressure within the established range; in addition, the system allows the user to set the overpressure alarm threshold. Once the pressure is detected to exceed the threshold, the controller immediately issues an alarm and cuts off the pump power to ensure safe operation.

[0003] However, existing technologies still suffer from inaccurate flow measurement in batch production. During frequent starts and stops, the mechanical inertia of the pump motor prevents the CO2 fluid from quickly entering or exiting a stable flow state. This causes transient shocks during the start-stop transition phase to appear as high-amplitude, irregular pulse fluctuations at the flow sensor. Because the system lacks effective identification and elimination of these transient interference signals, the accumulated flow data is mixed with a large number of non-transfer pulses, which cannot truly reflect the actual flow rate, seriously affecting the proportioning accuracy and experimental reproducibility of subsequent processes. Summary of the Invention

[0004] In order to overcome the above-mentioned defects of the prior art, the present invention provides a carbon dioxide booster pump control system and method, which solves the problem of delivery error caused by batch start and stop by performing timestamp mapping separation on the start and stop interference pulses, extracting incremental accumulation by sliding median filtering peak value, and combining temperature and pressure compensation.

[0005] To achieve the above objectives, the present invention provides the following technical solutions: a carbon dioxide booster pump control system, comprising:

[0006] The flow rate management module includes a constant flow control unit and a constant pressure control unit. The constant flow control unit is used to set a constant flow rate and equilibrium time, controlling the carbon dioxide booster pump to increase the set flow rate in stages to the target value and maintain a constant output; the constant pressure control unit is used to set control parameters and dynamically adjust the flow rate to stabilize the pressure within the target pressure ± error range;

[0007] The temperature control module collects the actual temperature through the temperature sensor and starts and stops the refrigeration system according to the set temperature to achieve temperature control;

[0008] The safety monitoring module includes a pressure monitoring unit and an overpressure protection unit. The pressure monitoring unit uses a pressure sensor to collect and display the pressure of the CO2 booster pump in real time. The overpressure protection unit sets an upper pressure threshold, triggering automatic shutdown and pop-up alarms when the upper pressure threshold is exceeded, and continuously monitors the pressure status.

[0009] The interactive display module dynamically generates and displays the real-time flow rate change curve, and displays the current running flow accumulation value and the total accumulated flow during the device power-on period in real time.

[0010] Preferably, the control parameters of the constant pressure control unit can be configured independently, and the control parameters include: flow rate upper limit, target pressure, pressure error range, flow rate adjustment amplitude and adjustment time; the constant pressure control unit executes the following process: if the actual pressure does not reach the target pressure ± error range, the flow rate is periodically adjusted to increase or decrease according to the set adjustment time; when the pressure reaches the upper limit of the error range, the flow rate is reduced to 0; when it is lower than the lower limit, the flow rate is increased by the set amplitude until it reaches the flow rate upper limit; the flow rate adjustment range is limited to 0 to the preset flow rate upper limit value;

[0011] Preferably, the constant flow control unit performs the following process: setting the initial flow rate to 0, linearly increasing it to the target flow rate within a preset equilibrium time, and maintaining a constant output.

[0012] Preferably, the overpressure protection unit is arranged in parallel with the mechanical unloading valve, and automatic shutdown protection is preferentially enabled when overpressure occurs. The overpressure protection unit comprises:

[0013] Overpressure pop-up alarm mechanism, when the pressure exceeds the limit, the alarm window will pop up;

[0014] If the pressure still exceeds the limit within 1 minute after the window is closed, the alarm window will automatically pop up again;

[0015] When the pressure exceeds the limit, the pump is forced to stop without triggering the mechanical unloading valve.

[0016] Preferably, the system further includes a flow data calibration module, which receives the original pulse signal from the flow sensor, distinguishes between transient interference pulses and steady-state pulse signals; performs sliding median filtering on the steady-state pulse signal to extract the true delivery peak; accumulates the filtering results in chronological order, compares the accumulated results with the auxiliary monitoring data in parallel, identifies and corrects the accumulated deviation caused by environmental changes, and thereby obtains the true flow data. The operation process of the flow data calibration module includes the following steps:

[0017] Step S1: while monitoring the motor start and stop signals in real time, the original pulses output by the flow sensor are time-stamped to separate the start and stop transient interference pulses;

[0018] Step S2: Automatically identify and isolate transient interference pulses based on the marked timing segments, and store them in a dedicated buffer to prevent them from participating in subsequent accumulation;

[0019] Step S3: Apply sliding median filtering to the isolated steady-state pulse signal to extract the true transmission peak value, so as to eliminate residual noise fluctuations and retain the pulse point that truly reflects the instantaneous transmission peak value. Sliding median filtering is performed according to a preset window, and the median result at the center position of each sliding window is used to extract the filtered peak value;

[0020] Step S4: Based on the filtered peak value, incremental accumulation is performed in chronological order, and the cumulative flow results of this and historical operations are updated in real time;

[0021] Step S5: Perform consistency check on the accumulated flow results and the auxiliary measurement data. If any deviation is found, the error correction mechanism is activated to partially compensate the historical data and output the real flow data.

[0022] Preferably, the process of identifying and correcting the accumulated deviation caused by environmental changes specifically includes the following steps:

[0023] Construct an aligned data set: Based on the time tag of the most recent peak accumulation, obtain the corresponding temperature and pressure measurements, and match them one by one with the current accumulation along the time axis to form a ternary aligned data set;

[0024] Calculate the temperature offset correction: input the difference between the temperature measurement value and the temperature setting value into the predefined temperature correction function, and output the temperature offset correction value;

[0025] Calculate the pressure offset correction: The difference between the measured pressure value and the upper pressure limit setting value is input into a custom pressure correction function, and the pressure offset correction value is output. The pressure correction function reflects the sensitivity change of pressure fluctuation to flow accumulation, achieving rapid response compensation for high-pressure disturbances.

[0026] Synthesized overall compensation pulse count: According to the pre-calibrated pulse volume conversion relationship, the temperature offset correction amount and the pressure offset correction amount are superimposed at a fixed weight and converted into the compensation pulse count within the current batch or historical cumulative amount matching period.

[0027] Preferably, before incremental accumulation is performed in chronological order based on the filtered peak value, a pulse signal screening unit is also included to perform a weighted operation on the skewness and peak ratio of the peak distribution of the current batch of steady-state pulse signals to generate a first judgment parameter reflecting the overall quality of the current batch of data; an operation is performed based on the ratio of the cumulative pulse slopes of the previous batches to the running time of the current batch segment to generate a second judgment parameter reflecting the consistency with the historical operation; the above two judgment parameters are input into a predefined mathematical model, and after processing, a decision signal is formed as to whether to eliminate the current batch of steady-state pulses; if the decision signal indicates elimination, the current batch of steady-state pulses as a whole will not participate in the subsequent accumulation, otherwise it will be included in the flow accumulation.

[0028] Preferably, the system further comprises a valve collaborative safety module, which evaluates the health status of the mechanical unloading valve by monitoring the pressure relief time constant of the mechanical unloading valve, activates the piezoelectric microvalve to collaboratively relieve pressure when performance degradation is detected, and performs valve core self-cleaning on the mechanical unloading valve after each pressure relief. When the accumulated risk exceeds the limit, the carbon dioxide booster pump is forced to shut down and lock;

[0029] The electric microvalve refers to a small electrically controlled valve based on a voltage ceramic actuator. Its channel cross-section is small. The ceramic piece is slightly deformed by applying voltage to open or close the channel. It is used to achieve fast and precise diversion or pressure relief control in high-pressure systems; the mechanical unloading valve refers to a safety valve that relies on a spring or weight mechanism and passively opens to release overpressure media when the system pressure reaches a preset threshold. Its operating principle is simple and it is resistant to high pressure, but it cannot achieve precise and controllable diversion and active closure.

[0030] Preferably, the valve collaborative safety module includes the following units:

[0031] Unloading valve action signal capture unit: During the pressure relief process of the mechanical unloading valve, the time data from the start of pressure relief to the pressure dropping to the safety threshold is collected in real time to generate the pressure relief time constant;

[0032] Health status dynamic assessment unit: Calculates the ratio of the pressure relief time constant to the reference time constant (the time required to complete the same pressure relief process when the valve is in a new state). When the ratio exceeds the set ratio (the set ratio is the upper limit of the ratio set according to the valve life curve), an alarm signal for unloading valve performance degradation is generated;

[0033] Dual-channel pressure relief coordinated control unit: upon receiving a performance degradation alarm signal, it automatically activates the parallel electric micro valves and sets the driving voltage of the electric micro valves according to the gradient of the pressure exceeding the standard;

[0034] Self-cleaning program trigger unit: After the pressure relief process is completed, the mechanical unloading valve is driven to perform high-frequency opening and closing actions to complete the preset number of sealing surface impurity removal operations;

[0035] Failure protection linkage response unit: When the performance degradation alarm signal is triggered a preset number of times within a single operating cycle, the power supply of the carbon dioxide booster pump group is forcibly cut off and the control interface is locked.

[0036] Preferably, the system also includes a multimodal safety interception module, which generates an overpressure warning through dynamic pressure trend prediction, activates a layered alarm interface and a multi-channel operation path (voice / physical knob), intelligently skips interaction and shuts down directly under extreme working conditions, and performs arbitration responses to multi-source shutdown commands.

[0037] To achieve the above objectives, the present invention provides the following technical solution: a carbon dioxide booster pump control method, comprising:

[0038] Step 1: Synchronously collect the motor start / stop signal and the flow sensor raw pulse, map them according to millisecond timestamps, and classify the corresponding pulses as transient interference within the preset time window before and after the event. The remaining pulses are aggregated as steady-state pulses.

[0039] Step 2: Perform sliding median filtering on the steady-state pulse set according to the preset window length and step size, and extract the filtered peak value from the center of each window to construct the real transmission peak sequence;

[0040] Step 3: Arrange the actual peak values in ascending order of time and add them up one by one to generate the current operation cumulative flow and historical cumulative flow in real time;

[0041] Step 4: Based on the time stamp of the last peak accumulation, obtain the corresponding readings from the temperature sensor and pressure sensor, calculate the temperature offset correction and pressure offset correction respectively, sum them with fixed weights, and convert them into compensated pulse counts based on the pulse-volume conversion relationship;

[0042] Step 5: Incorporate the compensation pulse count into the historical cumulative flow, update the real flow data, and record the cumulative flow and corresponding temperature and pressure data before and after compensation in the system log.

[0043] Technical effects and advantages of the present invention:

[0044] (1) The present invention maps the motor start / stop signal with the original pulse of the flow sensor to a millisecond-level timestamp and accurately isolates the transient interference pulse within a preset time window; applies sliding median filtering and peak extraction to construct a true delivery peak sequence; and implements incremental accumulation based on the sequence to achieve real-time online update of the cumulative flow of this operation and the historical cumulative flow, effectively eliminating the transient fluctuation error caused by mechanical inertia and pipeline elasticity, ensuring the high accuracy and continuity of the flow data, and thus significantly improving the delivery volume measurement reliability of the carbon dioxide booster pump under batch production conditions.

[0045] (2) The present invention constructs a ternary time-aligned temperature, pressure and flow data set, inputs the difference between the temperature measurement value and the set target temperature into a predefined temperature correction function to generate a temperature offset correction, and inputs the difference between the pressure measurement value and the set pressure upper limit into a custom pressure correction function to generate a pressure offset correction; in step six, the two types of corrections are summed up with a pre-calibrated fixed weight, and converted into a compensated pulse count based on the pulse-volume conversion relationship, thereby realizing fine correction of multi-source data fusion and significantly improving the system's automatic compensation capability for cumulative flow deviation and overall robustness under complex environmental fluctuation conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 This is a block diagram of the overall structure of the carbon dioxide booster pump control system of the present invention.

[0047] Figure 2 This is a flow chart of the flow data calibration module operation of the present invention.

[0048] Figure 3 This is a structural block diagram of the valve collaborative safety module of the present invention. DETAILED DESCRIPTION

[0049] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0050] At the same time, it should be understood that for the convenience of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship.

[0051] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the present disclosure, its application, or uses.

[0052] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0053] Background information: When a carbon dioxide booster pump performs batch production tasks, the equipment needs to be started and stopped frequently. Each time the pump motor starts running or stops, the fluid cannot immediately reach a stable flow state due to mechanical inertia. The instantaneous impact generated by this start-stop transition phase will cause the flow sensor to detect abnormal fluctuation signals, but these signals do not represent the actual flow data (carbon dioxide delivery volume).

[0054] Example 1, see Figure 1 The overall structural block diagram of the carbon dioxide booster pump control system, the present invention provides Figure 1 A carbon dioxide booster pump control system shown includes:

[0055] The flow rate management module includes a constant flow control unit and a constant pressure control unit. The constant flow control unit is used to set a constant flow rate and equilibrium time, controlling the carbon dioxide booster pump to increase the set flow rate in stages to the target value and maintain a constant output; the constant pressure control unit is used to set control parameters and dynamically adjust the flow rate to stabilize the pressure within the target pressure ± error range;

[0056] The temperature control module collects the actual temperature through the temperature sensor and starts and stops the refrigeration system according to the set temperature to achieve temperature control;

[0057] The safety monitoring module includes a pressure monitoring unit and an overpressure protection unit. The pressure monitoring unit uses a pressure sensor to collect and display the pressure of the CO2 booster pump in real time. The overpressure protection unit sets an upper pressure threshold, triggering an automatic shutdown and pop-up alarm when the limit is exceeded, and continuously monitors the pressure status.

[0058] The interactive display module dynamically generates and displays a real-time flow rate change curve, displays the current running flow accumulation value and the total accumulated flow during the device power-on period in real time, and in the embodiment of the present invention, displays and interacts centrally through a 7-inch display screen.

[0059] What needs to be further explained in the present invention is that the control parameters of the constant pressure control unit can be configured independently, and the control parameters include: flow rate upper limit, target pressure, pressure error range, flow rate adjustment amplitude and adjustment time; the constant pressure control unit executes the following process: if the actual pressure does not reach the target pressure ± error range, the flow rate is increased or decreased by periodic adjustment amplitude according to the set adjustment time; when the pressure reaches the upper limit of the error range, the flow rate drops to 0; when it is lower than the lower limit, the flow rate increases by the set amplitude until the flow rate upper limit; the flow rate adjustment range is limited to 0 to the preset flow rate upper limit value.

[0060] It should be further explained in the present invention that the constant flow control unit performs the following process: setting the initial flow rate to 0, linearly increasing it to the target flow rate within a preset equilibrium time, and maintaining a constant output.

[0061] It is necessary to further explain that in the present invention, the overpressure protection unit is arranged in parallel with the mechanical unloading valve, and automatic shutdown protection is preferentially enabled when overpressure occurs; the overpressure protection unit comprises:

[0062] Overpressure pop-up alarm mechanism, when the pressure exceeds the limit, the alarm window will pop up;

[0063] If the pressure still exceeds the limit within 1 minute after the window is closed, the alarm window will automatically pop up again;

[0064] When the pressure exceeds the limit, the pump is forced to stop without triggering the mechanical unloading valve.

[0065] It is necessary to further explain in the present invention that, before the interactive display module, the system further includes a flow data calibration module for receiving the original pulse signal from the flow sensor, distinguishing between transient interference pulses and steady-state pulse signals; performing sliding median filtering on the steady-state pulse signal to extract the true delivery peak; accumulating the filtering results in chronological order, comparing the accumulated results with the auxiliary monitoring data in parallel, identifying and correcting the accumulated deviations caused by environmental changes, and thus obtaining the true flow data; refer to Figure 2 The flow data calibration module operation flow chart is as follows. The operation process of the flow data calibration module includes the following steps:

[0066] Step S1: while monitoring the motor start and stop signals in real time, the original pulses output by the flow sensor are time-stamped to separate the start and stop transient interference pulses;

[0067] Explanation: During the batch production process, the start and stop of the motor will generate fluid shock in a short period of time, causing non-delivery pulses to be mixed into the original pulse signal output by the sensor. If this is not distinguished, it will be difficult to eliminate transient interference in subsequent data processing. By synchronously collecting the original pulse signal output by the flow sensor and the motor start and stop signals, an original pulse set and an event type set are respectively formed, and the two are mapped one-to-one according to the millisecond time axis. For each start or stop event in the event type set, the pre-set time window is used as the boundary to divide the time period before and after the event, and the original pulses in the corresponding time period are marked as a transient pulse set, and the remaining pulses are classified as a steady-state pulse set.

[0068] Step S2: Automatically identify and isolate transient interference pulses based on the marked timing segments, and store them in a dedicated buffer to prevent them from participating in subsequent accumulation;

[0069] Explanation: After completing the division of transient and steady-state pulses, the interference pulses must be immediately isolated to avoid affecting the cumulative statistics, and to ensure that subsequent processing is performed only on the real transmission signal.

[0070] Step S3: Apply sliding median filtering to the isolated steady-state pulse signal to extract the true transmission peak value, so as to eliminate residual noise fluctuations and retain the pulse point that truly reflects the instantaneous transmission peak value. Sliding median filtering is performed according to a preset window, and the median result at the center position of each sliding window is used to extract the filtered peak value;

[0071] Explanation: Using a steady-state pulse signal set as input, subsequences are sequentially intercepted according to a predetermined sliding window length and sliding step size. The pulse count values within each subsequence are sorted by size and their median values are taken to generate the corresponding median filtering results, thus constructing a filtered pulse set. Within the filtered pulse set, the peak counts corresponding to the center position of each sliding window are identified and extracted one by one to be included in the true transmission peak set.

[0072] Step S4: Based on the filtered peak value, incremental accumulation is performed in chronological order, and the cumulative flow results of this and historical operations are updated in real time;

[0073] Step S5: Perform consistency check on the accumulated flow results and the auxiliary measurement data. If any deviation is found, the error correction mechanism is activated to partially compensate the historical data and output the real flow data.

[0074] Scenario overview: After completing the accumulation of flow peak increments, fluctuations in ambient temperature and system pressure can cause deviations in the accumulated results. Therefore, it is necessary to fine-tune the accumulated amount in combination with auxiliary measurement data to ensure the accuracy of the final flow data and the repeatability of system operation.

[0075] It is further explained that the process of identifying and correcting the accumulated deviation caused by environmental changes specifically includes the following steps:

[0076] Construct an aligned data set: Based on the time tag of the most recent peak accumulation, obtain the corresponding temperature and pressure measurements, and match them one by one with the current accumulation along the time axis to form a ternary aligned data set;

[0077] Calculate the temperature offset correction: input the difference between the temperature measurement value and the temperature setting value into the predefined temperature correction function, and output the temperature offset correction value;

[0078] Calculate the pressure offset correction: The difference between the measured pressure value and the upper pressure limit setting value is input into a custom pressure correction function, and the pressure offset correction value is output. The pressure correction function reflects the sensitivity change of pressure fluctuation to flow accumulation, achieving rapid response compensation for high-pressure disturbances.

[0079] Synthesized overall compensation pulse count: According to the pre-calibrated pulse volume conversion relationship, the temperature offset correction amount and the pressure offset correction amount are superimposed at a fixed weight and converted into the compensation pulse count within the current batch or historical cumulative amount matching period.

[0080] The explanation shows that the pressure correction function is used to convert the pressure deviation into a volume correction. The input is the pressure deviation at the current moment, and the output is the corresponding pressure offset correction. The solution process of the pressure correction function is: by recording the corresponding relationship between the actual cumulative error and the pressure deviation under multiple sets of typical pressure disturbance conditions, and using curve fitting to determine the baseline multiplication factor and exponential growth rate in the pressure correction function, so as to ensure that the pressure correction function can accurately reflect the impact of pressure deviation on flow error within the entire operating range.

[0081] The explanation shows that the temperature correction function is used to convert the temperature deviation into a volume correction. The input is the temperature deviation at the current moment, and the output is the corresponding temperature offset correction. The solution process of the temperature correction function is: by measuring the actual flow error under different temperature deviation conditions, and performing polynomial fitting on the actual flow error obtained by the least squares method, thereby obtaining the coefficients of the cubic term, quadratic term, linear term, and zero-order term, ensuring that the temperature correction function can capture the high-order nonlinear characteristics of the influence of temperature on flow.

[0082] Explanation: Through pre-designed multiple groups of temperature and pressure linkage experiments, flow measurement error data corresponding to changes in two environmental factors under typical operating conditions are collected; statistical analysis and variance decomposition methods are used on the flow measurement error data to evaluate the relative contribution of temperature fluctuations and pressure fluctuations to the error, and the weight parameters applicable under typical operating conditions are determined based on the relative contributions; the obtained weight parameters are directly used as constants in the compensation calculation; after completing the weighted superposition, relying on the pulse-volume conversion relationship obtained in the calibration stage, the combined overall compensation volume can be mapped to an equivalent number of pulses with one click, and it can be included in the historical accumulated value for a one-time correction.

[0083] It is explained that the pulse-volume conversion relationship is used to convert the volume correction amount into an equivalent number of pulses. The steps for solving the pulse-volume conversion relationship are: during the calibration phase, the pump is driven to operate under known volume conditions, and the total number of pulses output by the flow sensor is recorded at the same time. The conversion coefficient of volume corresponding to each unit pulse is obtained by the ratio of the two.

[0084] What needs to be further explained in the present invention is that before the incremental accumulation is performed in chronological order based on the filtered peak value, a pulse signal screening unit is also included to perform a weighted operation on the skewness and peak ratio of the peak distribution of the current batch of steady-state pulse signals to generate a first judgment parameter reflecting the overall quality of the current batch of data; an operation is performed based on the ratio of the cumulative pulse slopes of the previous batches to the running time of the current batch segment to generate a second judgment parameter reflecting the consistency with the historical operation; the above two judgment parameters are input into a predefined mathematical model, and after processing, a decision signal is formed as to whether to eliminate the current batch of steady-state pulses; if the decision signal indicates elimination, the current batch of steady-state pulses as a whole will not participate in the subsequent accumulation, otherwise it will be included in the flow accumulation.

[0085] Background information: During high-pressure operation of a CO2 booster pump, if the electronic overpressure protection system fails due to a circuit fault or program error, the mechanical unloading valve automatically opens to release pressure as a last resort. Repeated impacts from the high-pressure CO2 fluid cause the unloading valve's sealing components to gradually wear and age, resulting in reduced valve reset accuracy. Operators must manually check the valve status and reset the system, requiring the pump unit to be completely shut down for maintenance. This presents a dual safety hazard in the existing system, specifically:

[0086] The health status of the mechanical unloading valve is not monitored: After the mechanical unloading valve has been operated multiple times, wear on the sealing surface or impurities may become stuck, which may lead to pressure relief failure. However, the system cannot predict the deterioration of valve performance.

[0087] Inefficient fault handling: Manual reset requires complete shutdown, interrupting the production process, and operators face safety risks from close contact with high-voltage components.

[0088] When the electronic protection system fails, the unloading valve becomes the only protection method, and there is no coordinated state feedback mechanism between the two. Based on this, the second embodiment of the present invention is set up;

[0089] Example 2 differs from Example 1 in that the system further includes a valve coordination safety module, which assesses the health of the mechanical unloading valve by monitoring its pressure relief time constant. When performance degradation is detected, the piezoelectric microvalve is activated for coordinated pressure relief. The valve core of the mechanical unloading valve is self-cleaned after each pressure relief event. When the accumulated risk exceeds a limit, the carbon dioxide booster pump is forcibly shut down and locked.

[0090] The electric microvalve refers to a small electrically controlled valve based on a voltage ceramic actuator. Its channel cross-section is small. The ceramic piece is slightly deformed by applying voltage to open or close the channel. It is used to achieve fast and precise diversion or pressure relief control in high-pressure systems; the mechanical unloading valve refers to a safety valve that relies on a spring or weight mechanism and passively opens to release overpressure media when the system pressure reaches a preset threshold. Its operating principle is simple and it is resistant to high pressure, but it cannot achieve precise and controllable diversion and active closure.

[0091] It is necessary to further explain in the present invention that Figure 3 The valve collaborative safety module structure diagram is shown, and the valve collaborative safety module includes the following units:

[0092] Unloading valve action signal capture unit: During the pressure relief process of the mechanical unloading valve, the time data from the start of pressure relief to the pressure dropping to the safety threshold is collected in real time to generate the pressure relief time constant;

[0093] Health status dynamic assessment unit: Calculates the ratio of the pressure relief time constant to the reference time constant (the time required to complete the same pressure relief process when the valve is in a new state). When the ratio exceeds the set ratio (the set ratio is the upper limit of the ratio set according to the valve life curve), an alarm signal for unloading valve performance degradation is generated;

[0094] Dual-channel pressure relief coordinated control unit: upon receiving a performance degradation alarm signal, it automatically activates the parallel electric micro valves and sets the driving voltage of the electric micro valves according to the gradient of the pressure exceeding the standard;

[0095] Explanation: After receiving the performance degradation alarm signal, the difference between the current pipeline pressure value and the set safety threshold is calculated to obtain the pressure excess amplitude, and the pressure excess amplitude is mapped to several pre-divided intervals. Each interval corresponds to an electric microvalve channel with a different opening (each interval corresponds to a different driving voltage). The driving voltage is applied to different electric microvalve channels according to the gradient to achieve graded opening, and the pressure relief effect is continuously monitored until the pipeline pressure stabilizes within a safe range.

[0096] Self-cleaning program trigger unit: After the pressure relief process is completed, the mechanical unloading valve is driven to perform high-frequency opening and closing actions to complete the preset number of sealing surface impurity removal operations;

[0097] The explanation is that after the electric microvalve or a single mechanical unloading valve completes pressure relief, a high-frequency opening and closing control signal is sent to the mechanical unloading valve actuator. The valve core is driven to open and close repeatedly within the micro-stroke range a preset number of times, generating friction between the sealing surfaces to remove impurities. After the self-cleaning action is completed, the valve is reset to the closed state and the reference time constant is updated. The high-frequency opening and closing times are the number of cleaning cycles calibrated based on the amount of impurity deposits and valve durability. The micro-stroke range is the force range sufficient to cause friction between the sealing surfaces without affecting the structural integrity of the valve.

[0098] Failure protection linkage response unit: When the performance degradation alarm signal is triggered a preset number of times within a single operating cycle, the power supply of the carbon dioxide booster pump group is forcibly cut off and the control interface is locked.

[0099] What needs to be further explained in the present invention is that in order to solve the problem that when an overpressure pop-up window pops up, the window must be manually closed before other functions (such as emergency stop) can be operated, in an emergency condition, the operator may accidentally touch the pop-up window close button, resulting in the inability to intervene in time during repeated alarms in a short period of time (for example, within 1 minute); the system also includes a multimodal safety interception module, which generates an overpressure warning through dynamic pressure trend prediction, activates a layered alarm interface and a multi-channel operation path (voice / physical knob), intelligently skips the interaction and directly shuts down under extreme conditions, and performs arbitration responses to multi-source shutdown instructions.

[0100] It is necessary to further explain in the present invention that the multimodal security interception module specifically includes the following units:

[0101] Dynamic pressure trend prediction unit: collects pressure values in real time and calculates the pressure change rate per unit time. When the pressure change rate exceeds the preset pressure change rate threshold, a first-level overpressure warning signal is generated;

[0102] Hierarchical alarm interface activation unit: Based on the first-level overpressure warning signal, a floating alarm pop-up window is displayed in the top 20% of the touch screen area, and a red emergency stop virtual button is stationed in the bottom 10% area. The two interface layers do not overlap each other;

[0103] Voice command channel activation unit: During the display of the floating alarm pop-up window, it continuously monitors the voice signal input by the microphone and generates a voice command trigger signal when the preset emergency stop keyword is recognized;

[0104] Physical knob priority response unit: monitors the rotation angle of the mechanical emergency knob independent of the touch screen. If the knob is rotated clockwise more than 45 degrees, it directly generates a hardware shutdown command and cuts off the main power supply.

[0105] Intelligent suppression unit: When the pressure value continues to rise and reaches 95% of the preset burst pressure threshold, all interactive links are skipped and a forced shutdown command is immediately generated;

[0106] Multi-channel instruction execution arbitration unit: receives any one of the voice instruction trigger signal, hardware shutdown instruction, and forced shutdown instruction, drives the pump motor to cut off power and records the shutdown reason code.

[0107] It is necessary to further explain in the present invention that an embodiment of the present invention provides a carbon dioxide booster pump control method, comprising the following steps:

[0108] Step 1: Synchronously collect the motor start / stop signal and the flow sensor raw pulse, map them according to millisecond timestamps, and classify the corresponding pulses as transient interference within the preset time window before and after the event. The remaining pulses are aggregated as steady-state pulses.

[0109] Step 2: Perform sliding median filtering on the steady-state pulse set according to the preset window length and step size, and extract the filtered peak value from the center of each window to construct the real transmission peak sequence;

[0110] Step 3: Arrange the actual peak values in ascending order of time and add them up one by one to generate the current operation cumulative flow and historical cumulative flow in real time;

[0111] Step 4: Based on the time stamp of the last peak accumulation, obtain the corresponding readings from the temperature sensor and pressure sensor, calculate the temperature offset correction and pressure offset correction respectively, sum them with fixed weights, and convert them into compensated pulse counts based on the pulse-volume conversion relationship;

[0112] Step 5: Incorporate the compensation pulse count into the historical cumulative flow, update the real flow data, and record the cumulative flow and corresponding temperature and pressure data before and after compensation in the system log.

[0113] Finally: The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A carbon dioxide booster pump control system, characterized in that: include: The flow rate management module includes a constant flow control unit and a constant pressure control unit. The constant flow control unit is used to set a constant flow rate and equilibrium time, controlling the carbon dioxide booster pump to increase the set flow rate in stages to the target value and maintain a constant output; the constant pressure control unit is used to set control parameters and dynamically adjust the flow rate to stabilize the pressure within the target pressure ± error range; The temperature control module collects the actual temperature through the temperature sensor and starts and stops the refrigeration system according to the set temperature to achieve temperature control; The safety monitoring module includes a pressure monitoring unit and an overpressure protection unit. The pressure monitoring unit uses a pressure sensor to collect and display the pressure of the CO2 booster pump in real time. The overpressure protection unit sets an upper pressure threshold, triggering automatic shutdown and pop-up alarms when the upper pressure threshold is exceeded, and continuously monitors the pressure status. The flow data calibration module receives the original pulse signal from the flow sensor and distinguishes between transient interference pulses and steady-state pulse signals; Perform sliding median filtering on the steady-state pulse signal to extract the true transmission peak value; Based on the incremental accumulation of filtering results in chronological order, the accumulated results are compared with the auxiliary monitoring data in parallel to identify and correct the accumulated deviations caused by environmental changes, thereby obtaining the real flow data; The interactive display module dynamically generates and displays the real-time flow rate change curve, and displays the current running flow accumulation value and the total accumulated flow during the device power-on period in real time.

2. A carbon dioxide booster pump control system according to claim 1, characterized in that: The control parameters of the constant pressure control unit can be configured independently, and the control parameters include: flow rate upper limit, target pressure, pressure error range, flow rate adjustment amplitude and adjustment time; the constant pressure control unit executes the following process: if the actual pressure does not reach the target pressure ± error range, the flow rate is periodically adjusted according to the set adjustment time to increase or decrease the flow rate; when the pressure reaches the upper limit of the error range, the flow rate drops to 0; when it is lower than the lower limit, the flow rate increases according to the set amplitude until the flow rate upper limit; the flow rate adjustment range is limited to 0 to the preset flow rate upper limit value; the constant flow control unit executes the following process: the initial flow rate is set to 0, and it increases linearly to the target flow rate within the preset balance time, and maintains a constant output.

3. A carbon dioxide booster pump control system according to claim 1, characterized in that: The overpressure protection unit is arranged in parallel with the mechanical unloading valve. Automatic shutdown protection is activated first when overpressure occurs. The overpressure protection unit includes: Overpressure pop-up alarm mechanism, when the pressure exceeds the limit, the alarm window will pop up; If the pressure still exceeds the limit within 1 minute after the window is closed, the alarm window will automatically pop up again; When the pressure exceeds the limit, the pump is forced to stop without triggering the mechanical unloading valve.

4. A carbon dioxide booster pump control system according to claim 1, characterized in that: The operation process of the flow data calibration module includes the following steps: Step S1: while monitoring the motor start and stop signals in real time, the original pulses output by the flow sensor are time-stamped to separate the start and stop transient interference pulses; Step S2: Automatically identify and isolate transient interference pulses based on the marked timing segments, and store them in a dedicated buffer to prevent them from participating in subsequent accumulation; Step S3: Apply sliding median filtering to the isolated steady-state pulse signal to extract the true transmission peak value, so as to eliminate residual noise fluctuations and retain the pulse point that truly reflects the instantaneous transmission peak value. Sliding median filtering is performed according to a preset window, and the median result at the center position of each sliding window is used to extract the filtered peak value; Step S4: Based on the filtered peak value, incremental accumulation is performed in chronological order, and the cumulative flow results of this and historical operations are updated in real time; Step S5: Perform consistency check on the accumulated flow results and the auxiliary measurement data. If any deviation is found, the error correction mechanism is activated to partially compensate the historical data and output the real flow data.

5. A carbon dioxide booster pump control system according to claim 4, characterized in that: The process of identifying and correcting the accumulated deviations caused by environmental changes specifically includes the following steps: Construct an aligned data set: Based on the time tag of the most recent peak accumulation, obtain the corresponding temperature and pressure measurements, and match them one by one with the current accumulation along the time axis to form a ternary aligned data set; Calculate the temperature offset correction: input the difference between the temperature measurement value and the temperature setting value into the predefined temperature correction function, and output the temperature offset correction value; Calculate the pressure offset correction: The difference between the measured pressure value and the upper pressure limit setting value is input into a custom pressure correction function, and the pressure offset correction value is output. The pressure correction function reflects the sensitivity change of pressure fluctuation to flow accumulation, achieving rapid response compensation for high-pressure disturbances. Synthesized overall compensation pulse count: According to the pre-calibrated pulse volume conversion relationship, the temperature offset correction amount and the pressure offset correction amount are superimposed at a fixed weight and converted into the compensation pulse count within the current batch or historical cumulative amount matching period.

6. A carbon dioxide booster pump control system according to claim 4, characterized in that: Before incremental accumulation is performed in chronological order based on the filtered peak value, a pulse signal screening unit is also included to perform a weighted operation on the skewness and peak ratio of the peak distribution of the current batch of steady-state pulse signals to generate a first judgment parameter reflecting the overall quality of the current batch of data; an operation is performed based on the ratio of the cumulative pulse slopes of the previous batches to the running time of the current batch to generate a second judgment parameter reflecting the consistency with the historical operation; the above two judgment parameters are input into a predefined mathematical model, and after processing, a decision signal is formed as to whether to eliminate the current batch of steady-state pulses; if the decision signal indicates elimination, the current batch of steady-state pulses as a whole will not participate in the subsequent accumulation, otherwise it will be included in the flow accumulation.

7. A carbon dioxide booster pump control system according to any one of claims 1 to 6, characterized in that: The system also includes a valve coordination safety module that assesses the health of the mechanical unloading valve by monitoring its pressure relief time constant. When performance degradation is detected, the piezoelectric microvalve is activated for coordinated pressure relief. The valve core of the mechanical unloading valve is self-cleaned after each pressure relief event. When the accumulated risk exceeds a limit, the carbon dioxide booster pump is forced to shut down and lock. The electric microvalve refers to a small electrically controlled valve based on a voltage ceramic actuator. Its channel cross-section is small. The ceramic piece is slightly deformed by applying voltage to open or close the channel. It is used to achieve fast and precise diversion or pressure relief control in high-pressure systems; the mechanical unloading valve refers to a safety valve that relies on a spring or weight mechanism and passively opens to release overpressure media when the system pressure reaches a preset threshold. Its operating principle is simple and it is resistant to high pressure, but it cannot achieve precise and controllable diversion and active closure.

8. A carbon dioxide booster pump control system according to claim 7, characterized in that: The valve collaborative safety module includes the following units: Unloading valve action signal capture unit: During the pressure relief process of the mechanical unloading valve, the time data from the start of pressure relief to the pressure dropping to the safety threshold is collected in real time to generate the pressure relief time constant; Health status dynamic assessment unit: calculates the ratio of the pressure relief time constant to the reference time constant. When the ratio exceeds the set ratio, it generates an alarm signal for the performance degradation of the unloading valve. Dual-channel pressure relief coordinated control unit: upon receiving a performance degradation alarm signal, it automatically activates the parallel electric micro valves and sets the driving voltage of the electric micro valves according to the gradient of the pressure exceeding the standard; Self-cleaning program trigger unit: After the pressure relief process is completed, the mechanical unloading valve is driven to perform high-frequency opening and closing actions to complete the preset number of sealing surface impurity removal operations; Failure protection linkage response unit: When the performance degradation alarm signal is triggered a preset number of times within a single operating cycle, the power supply of the carbon dioxide booster pump group is forcibly cut off and the control interface is locked.

9. A carbon dioxide booster pump control system according to claim 1, characterized in that: The system also includes a multimodal safety interception module that generates overpressure warnings through dynamic pressure trend prediction, activates a layered alarm interface and multi-channel operation paths, intelligently skips interactions and directly shuts down under extreme operating conditions, and performs arbitration responses to multi-source shutdown commands.

10. A carbon dioxide booster pump control method, used to implement the system according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1: Synchronously collect the motor start / stop signal and the flow sensor raw pulse, map them according to millisecond timestamps, and classify the corresponding pulses as transient interference within the preset time window before and after the event. The remaining pulses are aggregated as steady-state pulses. Step 2: Perform sliding median filtering on the steady-state pulse set according to the preset window length and step size, and extract the filtered peak value from the center of each window to construct the real transmission peak sequence; Step 3: Arrange the actual peak values in ascending order of time and add them up one by one to generate the current operation cumulative flow and historical cumulative flow in real time; Step 4: Based on the time stamp of the last peak accumulation, obtain the corresponding readings from the temperature sensor and pressure sensor, calculate the temperature offset correction and pressure offset correction respectively, sum them with fixed weights, and convert them into compensated pulse counts based on the pulse-volume conversion relationship; Step 5: Incorporate the compensation pulse count into the historical cumulative flow, update the real flow data, and record the cumulative flow and corresponding temperature and pressure data before and after compensation.

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